How to build a full carbon surffoil board: Part 1

[@CrushersRide]

Nice first time job! Some production tips that I hope will help For foil boards consider taking out the outline of the box from top to bottom and just do a wet layup with a 2"+ flange, then reinsert the cutout foam and box. Much less likely to to crack the box when pumping with a connected I-beam/cylinder internal to the board. Plus it's much easier! Second, nice that you choose to do bottom first, after you've wet out the cut cloth as close to the down side of the rail as you can will save you a great deal of finish work. you've probably figured out that using a pair of work gloves can be a life saver when removing peel-ply those carbon splinters can really get in there.

[@neilturner2694]

Cool looking forward to part 2 and part 3 that jou take it on the water.

[@plantwithroos]

Super awesome!!! It was such a fun process to help with ❤️❤️❤️

[@TheIrishalf]

Question about the Fitting of rail box. Boxed the carbon and linked in to the bottom of layers of carbon on board. Still holding up no issues. Thinking of using this method myself. Rather than top deck link. So I don’t have to cut big chunks of foam out. Kite Wing surf board making

[@Dzjiefoils]

It’s still holding up! The whole board is performing very good! It’s rock solid. No issues so far.

[@lucacorsi1818]

Sorry, please tell me how much you set the vacuum depression valve. ( to avoid wasting polystyrene )

[@Dzjiefoils]

Just below 0 bar. I think it’s -0.2 or something

[@brunogiuntoli2604]

Nice job, specially being able to work in your kitchen ;). I suggest using a mask, specially on those CF sanding parts.

[@Dzjiefoils]

Thanks for the advice, you are not the first one recommending this. I will use one next time! Working in the kitchen is not ideal. I would prefer working in my shed, but the temperatures where to low for the epoxy to cure properly.

[@ahmedtymour6301]

How are u using epoxy directly over foam, epoxy melt foam no??

[@Dzjiefoils]

No, epoxy doesn’t hurt EPS foam.

[@GJ-display-repair]

What is the vacuum pump brand and model , Thanks

[@Dzjiefoils]

Hi, I have no idea what kind of pump it is. I borrowed it at work. I recently bought my own pump. I will take a look in the shed this weekend to find out what brand it is.

[@blooskyy7]

Were three layers of carbon needed or do you think one layer plus a layer of 6oz would be sufficient? With extra layers around the foil track.

[@Dzjiefoils]

Three layers is complete overkill, I was told after the build. The most important part is the area around the box. Add strength there and then 1 layer of carbon should do the trick. If you read further down in the comments there is someone who has some pointers about the carbon layers.

[@blooskyy7]

@@Dzjiefoils Thanks, busy with a build too and that's what I was thinking

[@Dzjiefoils]

Nice! Is it your first build?

[@REDboardriders]

Such a good video!

[@Dzjiefoils]

Thanks!… I think the whole process can go a lot quicker. Maybe ill make another vid soon.

[@ahit1027]

Hi ! Nice build ! Quick question, whats up with covering thé fiber up when curing ?

[@Dzjiefoils]

It is covered with peelply, (that lets the excess resin through and you rip it off when cured). Then absorber cloth that takes the excess resin. Then it’s put in the vacuüm bag.

[@alleew.5922]

Is it still holding up 2 years later?

[@Dzjiefoils]

Yes! It's doing fine! It's so solid because of the multiple carbon layers that its is almost unbreakable. I recently made another foil board that I now use more than this one because of the shape. The new board catches waves a lot better so I can surf on even smaller swells.

[@enricotoscano2079]

Excuse me....could you link where I can found eps 200? Thanks...in your opinion I could do the same using eps 100?

[@Dzjiefoils]

I found my eps 200 blocks on marktplaats.nl. Some building company’s sell them as leftover insulation material thats used to insulate concrete floors. Marktplaats.nl is a website for individuals who sell 2nd hand stuff. I think you could manage to do it with eps 100. You only have te be more careful during the shaping process. It has a lower density so eps100 will have bigger and more fragile tempex balls.

[@ahmedtymour6301]

What foam density are u using ..?

[@Dzjiefoils]

This is EPS 200.

[@surfphilosophy01]

Nice work man. What's that yellow foam you inserted on EPs? Divinicell?

[@Dzjiefoils]

You mean the foam around the finboxes?

[@surfphilosophy01]

Yes. Exactly

[@Dzjiefoils]

I bought it with the foam Attached to them. But I googled your divinycell and it looks a lot like that! You can also buy them from China: m.nl.aliexpress.com/item/1005001684964693.html?spm=a2g0n.productlist.0.0.3d7151d6Pnwj79&browser_id=8d839e1e7a9a4d5cbe371f4df68d86fd&aff_trace_key=&aff_platform=msite&m_page_id=c9efsd47cccayzbl179aa060b7323f65f23c1e2891&gclid=&_imgsrc_=ae01.alicdn.com%2Fkf%2FH0a8b41901eca4d288d342f213606e272q.jpg_640x640Q90.jpg

[@davidkolokotronis4456]

Do you have any dimensions that you can give me because im trying to make one

[@Dzjiefoils]

Mine is 4ft long 21 inches wide and 4 1/5 thick. I would build it a little bit longer if I where you. It makes it a little bit better to glide into the waves.

[@quepasatim]

Nice, but how did the fiberglass layer or what ever it was not stick to the carbon in the vacum bag????

[@Dzjiefoils]

I think you mean the peelply. It’s a cloth that lets the excess epoxy resin out of the carbon. So you have a near perfect carbon to resin ratio. Its meant to rip off the carbon after the resin cures.

[@quepasatim]

@@Dzjiefoils nice thanks ✌

[@michaelcasteleyn-uf1vm]

Nice everyone does things differently I would have not wrapped the fin box in carbon but thinking about it is probably a good idea I fill the boxes up with wax messier but easy you jus have to wash it out with hot water at the end I would have coated the foam blank with qcell slurry and resanded yer more work but maybe a bit lighter I would bad a layer of divincell on the deck But yer who knows the best way as there is nothing worse that snapping some thing and thinking yer on more layer of carbon would have been good

[@Dzjiefoils]

All great tips! The wrapping the finbox in carbon was kind off an accident I didn’t know at the time that the finbox should sit slightly above the foam so you can sand open later. I would have done it the same way now, but than sanding the box open. The qcell idea is great!

[@Dzjiefoils]

And some deck sandwich layer is now standard in my foil boards. Check out the latest foil board making video to see how I do stuff nowadays

[@elceibo846]

HI,,,, which is the material of the white block is telgopor? thanks

[@Dzjiefoils]

It’s tempex EPS 200

[@oriolsalablasi9154]

wich foam do you use?

[@Dzjiefoils]

Eps 200 building foam. It’s used to insulate floors. Concrete is poored over it.

[@davidszezhe]

nice man, did you buy the foil box on aliexpress?

[@Dzjiefoils]

No I bought it from a guy in Belgium. But I think the Aliexpress boxes are exactly the same

[@NCLSUGRT]

what kind of resin do you use so that it doesnt melt the foam

[@Dzjiefoils]

Nicolas Ugarte I just used normal epoxy resin from mr.Boat.nl. I don’t think the resin gets hot when u use the right amount of hardener. The epoxy takes 24h to dry. If you leave it in a cup it will get hot, but spread out over such a large surface it will heat up a lot less. At least that’s what i’m thinking. I’m not an expert

[@kanedalziel8263]

how hot resin are you using mate

[@stingerboardsfoilswings739]

nice clip

[@Dzjiefoils]

Thanks!

[@enzodebredo]

Gaaf hoor! Volgende keer wat surfmuziek eronder!

[@Dzjiefoils]

Staat genoteerd.

[@griggsdiemar6599]

Nice board, what type of vacuum pump did you use? Also, did you use a resin trap?

[@Dzjiefoils]

Thanks! I used a pump from the highschool where I work. I don’t know the exact specs. They just use it for small science experiments. I didn’t use a resin trap because I have the bleeder cloth, this takes all the excess epoxy.

[@griggsdiemar6599]

@@Dzjiefoils thank you so much

[@bricolrider2072]

nice work, make your foil insert you save money, nearly on my channel, enjoy your ride🤙

[@Dzjiefoils]

Thanks! I will take a look

[@jonaskahn2277]

Nice Board! What kind of carbon did you use? and Layers? Thanks

[@Dzjiefoils]

200 grams/m2 plain weave carbon 3 layers thick. Both the deck and the bottomside. But I think it can be strong enough with only 2 layers. Be sure to put them at a 45 degree angle to each other.

[@jonaskahn2277]

@@Dzjiefoils Ok Thanks. How many kg does the board weight? End result?

[@Dzjiefoils]

Jonas Kahn Just weigh’d it. Its 3.9kg’s.

[@Dzjiefoils]

With some wax on it.

[@jonaskahn2277]

@@Dzjiefoils What EPS foam density do you use?

[@jonaspalm8287]

What foam is it?? It looks like the foam you get in an Amazon package😅

[@Dzjiefoils]

It’s tempex EPS 200. Start saving those packages! 😜

[@wildebeast]

The Mann bun is so fubar

[@rz3877]

Mooie keuken wel

[@Dzjiefoils]

Bedankt heh! Gemaakt door een of ander timmermannetje.

[@АльфредМиннибаев-г8в]

Шкурить голыми руками карбон это найс!!!

[@ВладВладов-д4н]

Без стрингеров прогнется под ногами и сломается от нагрузок.

[@Dzjiefoils]

Well that didn’t happen yet, and I’m using this board for almost 3 years. The 3 layers of carbon do their work very well. No pressure dents, and a very stiff board!

[@ВладВладов-д4н]

@@Dzjiefoils класс! Очень красивая . Хорошо что все норме!

[@coolfiy2005]

2 pieces of carbon fiber cloth are enough. You used 4 layers of carbon fiber cloth.

[@Dzjiefoils]

Thanks for your reply. I used to much carbon indeed! In my next projects I will make sure I use less.

[@gregrandol2801]

Woodglut scripts contain most of the woodworking plans you can find.